PATTERN MATERIALS AND ALLOWANCES FOR PATTERNS

INTRODUCTION CASTING:

Foundry of casting is the process of producing components of desired shapes by pouring the molten metal into a prepared mould and then allowing the metal/allow to cool and solidify. The solidified piece of metal/alloy is known as casting.
MOULD :A mould is a container having a cavity of the shape to be cast. CORE:A Core is a body which is employed to produce a cavity in the casting.

INTRODRCTION TO PATTERN
1.A pattern is a mold forming tool 2.A pattern is a model or the replica of the object to bi cast. 3.Except for the various allowances a pattern exactly resembles the casting to be made. 4.A pattern is required even if one object has to be cast.
DIFFERNCE BETWEEN PATTERN AND CASTING:

The main difference between a pattern and the casting is as regards their dimensions. A pattern is slightly larger in size as compared to the casting,because a pattern,

PATTERN MATERIALS
The factors to be considered in selecting proper pattern materials: 1. The number of castings to be produced. 2. The desired dimensional accuracy and surface finish . 3. Method of molding 4. Shape, complexity and size of the casting. 5. Type of molding materials 6. The probability of changing the casting.

Materials Used for making patterns

Different types of materials that are used for making patterns are mentioned below. 1. Wood 2. Metal 3. Plastic 4. Wax WOOD:The most common materials for making patterns for sand casting is the wood. Advantages : 1. Easy availability 2. Light in weight 3. Easy to machine and to shape to different configurations. 4. Wood patterns can be preserved for quite long times 5. Wooden patterns can be repaired easily

Limitations: 1. Wooden patterns are susceptible to shrinkage and swilling. 2. They absorb moisture, consequently get warped and change shape and size. 3.They cannot withstand rough handling. 4.They are weak as compared the metal patterns. Applications: Wooden patterns are used where the number of castings to be produced is small and the pattern size is large.

Different types of woods wood to be used for making patterns should be free from knots and other common defects. The following wood may be used for making patterns: White Pine Mahogany Teak Deodar etc METALS: Advantages of metal patterns: 1. Unlike wooden patterns, they do not absorb moisture. 2. They posses life much longer than wooden patterns. 3. They can withstand rough handling. 4. They do not warp. 5. It is easy to obtain smooth surface finish.

PLASTICS Plastic pattern does not stick with mould material and can be easily taken out without spoiling the mould cavity. One of the best plastics used for making patterns is Epoxy resin.

Advantages: 1. Durable. 2. Provides a smooth surface 3. Moisture resistant 4. A plastic pattern does not involve any appreciable change in its size of shape. 5. Light weight. 6. Good strength. 7. Wear and corrosion resistant. 8. Provides good surface finish.

Limitations: 1.Plastic patterns are fragile 2.Plastic patterns may not work well when subject to conditions of severe shocks.

WAX:

Advantages: 1. Wax patterns provide very good surface finish. 2. They impart high accuracy to the castings. 3. After being molded the wax pattern is not taken out of the mould like other patterns rather the mould is inverted and heated, the molten wax comes out .Thus there is no chance of the mould cavity getting damaged whine removing the pattern.

PATTERN ALLOWANCES
A pattern is always larger in size as compared to the final casting,because it carries certain allowances due to metallurgical and mechanical reasons. The various pattern allowances are discussed below: 1. Shrinkage allowance. 2. Machine allowance. 3. Draft allowance. 4. Shake allowance.
SHRINKAGE ALLOWANCE:

Almost all cast metals shrink or contract volumetrically,after solidification and therefore the pattern to obtain a particular sized casting is made oversize by an amount equal to that of shrinkage or contraction.

2.

Different metals shrink at different rates because shrinkage is the property of the cast metal . 3. Shrinkage allowance for various cast metals is as follows: Grey cast iron ------- 6.95 to 10.4mm/mt White cast iron ------ 20.8 Malleable cast iron ------- 10.4 Steel ---------- 20.8 Aluminium ------- 17.0 Brass ----------- 15.3 Bronze ---------- 10.4 to 20.8 Zinc ----------- 24.0 4. Cast iron poured at higher temperatures will shrink more than that poured at low temperature. 5. Wood patterns used to make metallic patterns are given double allowance.

MACHINING ALLOWANCE: A casting is given an allowance for machining,because 1.Castings get oxidized in the mould and during heat treatment the scales thus formed need to be removed. 2.It is intended to remove surface roughness and other imperfections from the castings. 3.It is required to achieve exact casting dimensions. How much Machining allowance should be provided: 1. Nature of metal 2.Size and shape of the casting 3.The type of machining operation 4.Molding process employed

Machining allowances for various metals are as follows: Cast iron med castings ------- 3mm Large castings ------ 10mm Cast steel med castings -------- 4.5mm Large castings -------up to 12mm Non ferrous med castings -------- 1.2mm Large castings ------ 5mm
DRAFT ALLOWANCE:

Draft allowance is given so that the pattern can be easily removed from molding without damaging the mould cavity.

The amount of taper depends upon:

1.Shape and size of the pattern 2.Molding method 3.Mould materials 4.Draft allowance on internal and external surfaces. SHAKE ALLOWANCE: Patterns is shaken or rapped by striking the same with a wooden piece from side to side.

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